CHAPTER 1 MATERIAL STRUCTURE

MATERIALS TECHNOLOGY 1
JF 302 PREPARED BY : LIM YEE KAI DEPARTMENT of MECHANICAL ENGINEERING

Historical Eras Of Materials Science

Evolution of the design of materials with macrostructure and microstructure.

Chapter 1

INTRODUCTION

The Material World evolution of engineering materials with time Relative importance and evolution of civil and mechanical engineering materials

Industrial Revolution WW1 WW2 Cold War

IT

Why the Study of Materials is Important?

Latex collected from rubber tree

Rubber baby doll RM33/piece

Tyre Kumho KH18 (195-60-15): RM135/piece

Natural raw rubber Rubber surgical glove SMR 20: RM13/kg RM15/box
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Carburetor Slide Diaphragm RM300/piece

The Mars Rovers - Spirit and Opportunity

Spirit and Opportunity are made up of materials such as * Metals * Ceramics * Polymers * Composites * Semiconductors
5www.nasa.gov

1.1

What is Materials Science and Engineering?

Materials Science and Engineering Resultant Knowledge of Structure and Properties Materials Engineering Applied Knowledge of Materials

Materials Science Basic Knowledge of Materials

Composition means the chemical make-up of a material. Structure means a description of the arrangements of atoms or ions in a material. Synthesis is the process by which materials are made from naturally occurring or other chemicals. Processing means different ways for shaping materials into useful components or changing their properties.
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Material Engineering Designing the structure to achieve specific properties of materials.

Performance

Properties Materials Science Investigating the relationship between structure and properties of materials.

Synthesis & Processing

Synthesis &Processing

Structure Performance

Structure

Properties

Figure 1.3: The four components of the tetrahedron of materials science and engineering and their linear interrelationship.
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Figure 1.1 Application of the tetrahedron of materials science and engineering to sheet steels for automotive chassis. Note that the microstructure-synthesis and processing-composition are all interconnected and affect the performance-to-cost ratio
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2003 Brooks/Cole Publishing / Thomson Learning

1.2 Materials Science: Structure

Electronic structure of individual. Subatomic Atoms that defines interaction among atoms (interatomic bonding).

level

Atomic level Microscopic structure Macroscopic structure

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Arrangement of atoms in materials (for the same atoms can have different properties). Example: 2 forms of carbon: graphite and diamond. Arrangement of small grains of material that can be identified by microscopy. Structural elements that may be viewed with the naked eye.

1.2 Materials Science: Properties

Properties are the way the material responds to the environment and external forces.
Mechanic al

Chemical stability Properties

Electrical & Magnetic

Thermal

Optical

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Structure, Processing, & Properties

Properties depend on structure

ex: hardness vs structure of steel
(d)

6 00 5 00
Hardness (BHN) (c) (a)
30 mm 30 mm
Data obtained from Figs. 10.30(a) and 10.32 with 4 wt% C composition, and from Fig. 11.14 and associated discussion, Callister 7e. Micrographs adapted from (a) Fig. 10.19; (b) Fig. 9.30;(c) Fig. 10.33; and (d) Fig. 10.21, Callister 7e.

4 00 3 00 2 00

(b)
4 mm 30 mm

100 0.01 0.1

1 10 100 1000 Cooling Rate (C/s)

Processing can change structure

ex: structure vs cooling rate of steel
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TYPES OF MATERIALS

METAL COMPOSITE

CERAMIC

POLYMER SEMICONDUCTOR

SMART MATERIALS

BIOMATERIALS

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Six Major Classes of Materials

Some of these have descriptive subclasses. Classes have overlap, so some materials fit into more than one class.

Metals
Iron and Steel Alloys and Superalloys (e.g. aerospace applications) Intermetallic Compounds (high-T structural materials)

Ceramics
Structural Ceramics (high-temperature load bearing) Refractories (corrosion-resistant, insulating) Whitewares (e.g. porcelains) Glass Electrical Ceramics (capacitors, insulators, transducers, etc.) Chemically Bonded Ceramics (e.g. cement and concrete)
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The American Ceramics Society Outreach Web Page: http://www.acers.org/acers/aboutceramics.asp? id=outreach

http://www.yonden.co.jp/sikoku/e0ssg102.htm

Six Major Classes of Materials

Polymers
Plastics Liquid crystals Adhesives

Light Emitting Diodes

Electronic Materials
Silicon and Germanium III-V Compounds (e.g. GaAs) Photonic materials (solid-state lasers, LEDs)

Composites
Particulate composites (small particles embedded in a different material) Laminate composites (golf club shafts, tennis rackets, Damaskus swords) Fiber reinforced composites (e.g. fiberglass)

Biomaterials (really using previous 5, but biomimetic)

Man-made proteins (cytoskeletal protein rods or artificial bacterium) Biosensors (Au-nanoparticles stabilized by encoded DNA for anthrax detection) Drug-delivery colloids (polymer based) 14

A high-water-content mouldable hydrogel

1.3 Atomic structure

Sub-atomic Particle Proton Electron Neutron Mass (kg) 1.672 x 10-27 0.905 x 10-30 1.675 x 10-27 Relative mass 1 0 1 Electron Charge (C) 1.602 x 10-19 1.602 x 10-19 0 Relative charge +1 -1 0

1st shell
2nd shell 3rd shell Nucleus consist of proton and neutron Figure 1.4: Schematic representation of the Bohr atomic model

Atomic number (Z) indicates number of protons in the nucleus of an atom. The atomic number is characteristic of the chemical element. Atomic mass (A) number (atomic weight) is the sum of the masses of protons and neutrons (N) in a nucleus. Isotopes of an element have the same number of protons but a differing number of neutron, hence different mass numbers. Avogadros number, N0 is the number of atoms of an element in one kilomole (the mass number expressed in kg). N0 = 6.023 x 1026/kmol (or 6.023 x 1023/mol).

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1.3 Atomic structure

Element

Salt (NaCl)

Compound

Atom
Atomic structure

Mixture

Molecule

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1.4 Element periodical table

Electronegativity

12 Mg 24.31

ATOMIC NUMBER ATOMIC SYMBOL (ELEMENT) ATOMIC MASSES / WEIGHT

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Figure 1.2: The periodic table of the elements.

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1.4

The Periodic Table

All elements has been classified according to electron configuration in the periodic table. The elements are situated, with increasing atomic number in seven horizontal rows called periods. The arrangement is such that all elements in a given column or group have similar valence electron structures, as well as chemical and physical properties. By referring to the periodic table shown in Figure 2.3, GROUP VIIIA = inert gases which have filled electron shell and stable electron configuration. GROUP VIIA = one electron deficient from having stable structures and termed as the halogens. GROUP VIA = two electrons deficient from having stable structures. GROUP IA = one and two electrons in excess of stable structures and often called and IIA the alkali and alkaline earth metals. GROUP IIIB = are termed as transition metals, which have partially filled d electron to IIB states and in some cases one or two electron in the next higher energy shell. GROUP IIIA, = display characteristics between metals and non-metals by virtue of IV and VA their valence electron structure.
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1.5 Crystallized structure

1.5.1

Atom arrangement in materials

Atom arrangement

Molecular structures

Crystal structures

Amorphous structures

crystalline SiO2
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noncrystalline SiO2

Si

Oxygen

Simple Cubic (SC)

Total atom per unit cell = [ 8 corner x 1/8 (at the corner) ] = 1 atom/unit cell Example: Salt (NaCl)

1 atom/unit cell
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Body-Centered Cubic (BCC)

Total atom per unit cell = [ 1 (at center) ] + [ 8 corner x 1/8 (at the corner) ] = 2 atoms/unit cell Example: Cromium, Molybdenum, Titanium and Tungsten

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2 atoms/unit cell

Face-Centered Cubic (FCC)

Total atom per unit cell = [(at each face) x 6 faces] + [ 8 corner x 1/8 (at the corner) ] = 4 atoms/unit cell Example: Aluminium, Copper, Gold and Nickel

4 atoms/unit cell
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Hexagonal Close-Packed (HCP)

Total atom per unit cell = 3 (at the middle triangle) + [ 12 corner on top and bottom x 1/6 (at the corner) ] + [ (at face) x 2 (face; top & bottom) ] = 6 atoms/unit cell

Example: Beryllium, Magnesium and Zinc.

6 atoms/unit cell
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1.6.2 Classification of Materials-Based on Structure Single crystal - only one crystal (no grain boundaries) Crystalline - > one crystals. In each crystal, atoms or ions show a long-range periodic arrangement. Polycrystalline material - many crystals Grains are the crystals in a polycrystalline material. Grain boundaries are regions between grains of a polycrystalline material.

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Figure 8: Schematic representation of crystalline, polycrystalline, and amorphous material structures

1.7 Types of atomic and molecular bonds

Intreratomic bond (Strong)

Ionic bond Covalent bond Metallic bond

Primary bonds
Chemic al Bonds
Intermolecular bonds (Weak)

Secondary bonds
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Van Der Waals bond

Hydrogen bond

1.7.1

Ionic Bond

Metal transfers an electron to an atom (non metal) which needs extra electrons.
Exp: KNO3 (potassium nitrate),CuSO4 (copper sulfate), MgO (magnesium oxide), PbI2 (lead iodide), AgCl (silver chloride)

+ ve
Attraction

- ve

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1.7.2

Covalent Bond

Sharing of valence electrons

Exp: CERAMICS (Diamond, glass), ORGANIC materials (wood), and GAS [SO3 (sulfur triooxide),N2O (dinitrogen oxide),C2H4 (ethylene),NH3 (ammonia), CO2 (carbon dioxide)].

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Examples of covalent bonding

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Strong bond Hard poor electrical conductivity

Weak bond Brittle Better electrical conductivity

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1.7.3 Metallic Bond Electromagnetic interaction between delocalized electrons

metallic nuclei

electron sea

Valence electrons not bonded to particular atom but shared and free to drift through the entire metal
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1.7.4

Van Der Waals Bond

Electrostatic charge in adjacent atoms. It is present between long-chained molecules in polymers bonding the chains together. When stretched the bonds break easily causing the material to deform.

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1.7.5

Hydrogen Bond

Hydrogen bonds exist in water. +ve charge at hydrogen and -ve charge at oxygen. Weak bond between water molecules making the vaporising of water very easy.
Strong covalent bond Weak hydrogen bond

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Case Study
1.

2.

3.

Name the important factors in selecting materials for the frame of a mountain bike. Steel, aluminium, and titanium alloys have all been used as the primary metals in the structure of a bicycle; determine the major weaknesses and strengths of each. The more modern bikes are made of advanced composites. Explain why and name a specific composite used in the structure of a bike.

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Case Study Material Selection

Problem: Select suitable material for bicycle frame and fork.

Wood Carbon fiber Reinforced plastic Aluminum alloys Ti and Mg alloys

Steel and alloys

Low cost but Heavy. Less Corrosion resistance

Light and strong. But Cannot be shaped

Very light and Light, moderately Slightly better strong. No Strong. Corrosion Than Al corrosion. Resistance. alloys. But much Very expensive expensive expensive

Cost important? Select steel Properties important? Select CFRP

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